SOLUTION HEAT TREATMENT OR CONTINUOUS ANNEALING

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63/248, 171, filed on September 24, 2021, which is hereby incorporated by reference in its entirety.

FIELD

[0002] The present disclosure relates to metallurgy generally and more specifically to techniques for simultaneously performing a surface treatment operation and a heat treatment operation or continuous annealing operation on a metal substrate.

BACKGROUND

[0003] A variety of treatment processes can be useful for transforming metal substrates into processed metal products. The metal substrates may be subjected to one or more forming processes (e.g., roll-forming, stamping, etc.). For example, the metal substrates can be subjected to a continuous annealing process, a solution heat treatment process, a surface treatment process, a quenching process, or other suitable processes. The processes can improve certain characteristics of the metal substrates. The characteristics can include bond durability, hardness, corrosion resistance, or other suitable characteristics. In conventional processing techniques, the described processes are typically performed in sequence (i.e., one process at a time followed by a subsequent process, etc.). But, this sequential performance of processes may create shaped metal products with less than optimal characteristics or other performance indicators. Additionally, performing the processes in certain sequences may degrade a surface of the metal substrates. For example, performing a solution heat treatment subsequent to a surface treatment may destroy or otherwise degrade the effects of the surface treatment.

SUMMARY

[0004] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subj ect matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.

[0005] The present disclosure provides techniques, products, and methods for simultaneously performing a surface treatment operation along with a solution heat treatment operation or a continuous annealing operation to produce a processed metal product. An elongated metal substrate can be subjected to a solution heat treatment operation or a continuous annealing operation. Additionally, the elongated metal substrate can be subjected to a surface treatment operation. In some examples, the solution heat treatment operation or continuous annealing operation and the surface treatment operation can be performed simultaneously using super-heated steam while also heating the elongated metal substrate, for example. Optionally, a moisture content of the super-heated steam can be less than or equal to 10%. Optionally, the elongated metal substrate can be passed into a furnace that can include one or more nozzles for spraying super-heated steam onto the elongated metal substrate.

[0006] Optionally, the elongated metal substrate can include an aluminum alloy sheet (e.g., a sheet comprising a 2xxx alloy, a 5xxx alloy, a 6xxx alloy, a 7xxx alloy, etc.). Optionally, the elongated metal substrate can be subjected to a quenchant that can include water. The water can optionally include additives, such as Mn, Ce, Zr, Mo, a silicate, a silane, a sealant, or a combination thereof. Treatment with the quenchant may optionally create a surface layer on the elongated metal substrate that can include the additives. Optionally, the super-heated steam can include an inhibiting material, such as Mn, Ce, Zr, Mo, or a combination thereof, which may optionally be incorporated into or on a surface or surface layer of the elongated metal substrate. Additionally, the surface layer can include the inhibiting material.

[0007] Optionally, the processed metal product can include a surface layer produced by the solution heat treatment process or continuous annealing process and the surface treatment process. For example, the surface layer may include at least one of boehmite, bayerite, diaspore, or corundum. The surface layer can have a thickness that can be from 10 nm to 500 nm, such as from 10 nm to 20 nm, from 20 nm to 50 nm, from 50 nm to lOO nm, from 100 nm to 150 nm, from 150 nm to 200 nm, from 200 nm to 250 nm, from 250 nm to 300 nm, from 300 nm to 350 nm, from 350 nm to 400 nm, from 400 nm to 450 nm, or from 450 nm to 500 nm.

[0008] Optionally, the elongated metal substrate can include an aluminum alloy sheet metal tube. Optionally, the aluminum alloy sheetmetal tube can be prepared by roll-forming an aluminum alloy sheet metal into a tubular shape and welding edges of the tubular shape together to enclose the aluminum alloy sheetmetal tube, such as into a hollow cross-sectional shape. Optionally, the solution heat treatment process or continuous annealing process and the surface treatment process can be performed using a combination of flame pyrolysis and induction heating. Optionally, the solution heat treatment process or continuous annealing process and the surface treatment process can be performed subsequent to welding the elongated metal substrate to produce a metal tube. In some examples, a metal tube may be referred to as having a tubular shape or tubular cross-sectional shape. In some examples, a metal tube may be referred to as a metal pipe. In some examples, a metal tube has a tubular or hollow cross-sectional shape. For example, a metal tube may have a circular or non-circular cross-sectional shape defined by the metal and including an opening or hollow region within a perimeter defined by the metal. For example, a metal tube may have a circular, noncircular, oval, or polygonal (e.g., triagonal, quadrilateral, pentagonal, hexagonal, heptagonal, octagonal, etc.) cross-sectional shape, including regular or non-regular cross-sectional shapes. Metal tubes having non-circular cross-sectional shapes may have cross-sectional shapes with linear sections or curved sections, including concave and/or convex curved sections. In some examples, a metal tube may have a star-shaped cross-section or other cross-sectional shape including both concave and convex regions. In some examples, metal tubes having polygonal cross-sectional shapes can have imperfect shapes, such as where corners of the shape are rounded. In some examples, metal tubes may have a D-shaped cross-sectional shape, a flat-sided oval cross-sectional shape, a rectangular cross-sectional shape, a square cross-sectional shape, or a circular cross-sectional shape.

[0009] The present disclosure provides a metal product that can include an aluminum alloy sheetmetal substrate and a surface layer on the aluminum alloy sheetmetal substrate. The surface layer on the aluminum alloy sheet metal substrate can include at least one of boehmite, bayerite, diaspore, or corundum. The surface layer can have a thickness that can be from 10 nm to 500 nm, such as from lO nm to 20 nm, from 20 nm to 50 nm, from 50 nm to 100 nm, from lOO nm to 150 nm, from 150 nm to 200 nm, from 200 nm to 250 nm, from 250 nm to 300 nm, from 300 nm to 350 nm, from 350 nm to 400 nm, from 400 nm to 450 nm, or from 450 nm to 500 nm.

[0010] Optionally, the aluminum alloy sheet metal substrate can include a solution heat treatable aluminum alloy sheet metal substrate. For example, the aluminum alloy sheet metal substrate can include one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. Optionally, the surface layer can include at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant. Optionally, the surface layer can be generated by subjecting the aluminum alloy sheet metal substrate to super-heated steam that can be characterized by a moisture content of less than or equal to 10%. Optionally, the super-heated steam can include an inhibiting material that can include at least one of Mn, Ce, Zr, or Mo. Optionally, the surface lay er can be, at least in part, generated by exposing the aluminum alloy sheet metal substrate to an aqueous quenchant. Optionally, the quenchant can include water and at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant.

[0011] The present disclosure provides a roll-formed metal product, such as a roll-formed metal tubular, that can include a roll-formed aluminum alloy sheet metal and a surface layer on the aluminum alloy sheet metal. The surface layer on the roll-formed aluminum alloy sheet metal can include at least one of boehmite, bay erite, diaspore, or corundum. The surface layer can have a thickness that can be from 10 nm to 500 nm, such as from lO nm to 20 nm, from 20 nm to 50 nm, from 50 nm to 100 nm, from 100 nm to 150 nm, from 150 nm to 200 nm, from 200 nm to 250 nm, from 250 nm to 300 nm, from 300 nm to 350 nm, from 350 nm to 400 nm, from 400 nm to 450 nm, or from 450 nm to 500 nm.

[0012] Optionally, the roll-formed aluminum alloy sheet metal can include one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. Optionally, the surface layer can include at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant. Optionally, the roll-formed aluminum alloy sheet metal can be prepared by roll-forming an aluminum alloy sheet metal. Optionally, the roll-formed aluminum alloy sheet metal product can be a roll-formed aluminum alloy sheet metal tube, prepared by roll-forming an aluminum alloy sheet metal into a tubular shape and by welding edges of the tubular shape together to enclose the roll-formed aluminum alloy sheet metal tube. Optionally, the roll-formed aluminum alloy sheet metal tube can include a treated aluminum alloy sheet metal tube. The treated aluminum alloy sheetmetal can be subjected to a simultaneous solution heat treat or continuous annealing and surface treatment process using a combination of flame pyrolysis and induction heating, for example subsequent to welding the edges of the tubular shape together. [0013] Other objects and advantages will be apparent from the following detailed description of non-limiting examples.

BRIEF DESCRIPTION OF THE FIGURES

[0014] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0015] FIG. 1 provides a schematic illustration of an exemplary processing line for forming sheet metal from an elongated metal substrate that includes a simultaneous solution heat treat or continuous annealing and surface treatment operation.

[0016] FIG. 2 provides a schematic illustration of an exemplary processing line for rollforming a sheetmetal tube from an elongated metal substrate that includes a simultaneous solution heat treat or continuous annealing process and surface treatment operation.

[0017] FIG. 3 provides a schematic illustration of a sub-system of the exemplary processing line of FIG. 2 for making processed metal products using simultaneous solution heat treatment or continuous annealing and solution treatment operations.

[0018] FIG. 4 provides a sectional side-view of a furnace that can be used to simultaneously perform solution heat treatment or continuous annealing and surface treatment operations.

[0019] FIG. 5 provides a flowchart of a process to create a processed metal product by simultaneously performing solution heat treatment or continuous annealing and surface treatment operations using super-heated steam.

[0020] FIG. 6 provides a sectional side-view of a processed metal product having a surface layer that can be created by simultaneously performing solution heat treatment or continuous annealing and surface treatment operations with respect to the processed metal product.

DETAILED DESCRIPTION

[0021] Described herein are systems and methods for simultaneously performing a surface treatment operation along with a solution heat treatment operation or a continuous annealing operation on a metal product, such as by using super-heated steam while heating the metal product. The simultaneous solution heat treatment operation or continuous annealing and surface treatment operation can be performed on one or more elongated metal substrates (e.g., an aluminum alloy substrate). The super-heated steam canbe applied to the elongated metal substrate while undergoing heating in a furnace (e.g., where steam nozzles are included in the furnace), using various operations (e.g., flame pyrolysis, etc.), or using other suitable techniques. Sub sequent to the simultaneous solution heat treatment operation or continuous annealing operation and surface treatment operation, the elongated metal substrate can be formed into various processed metal products. For example, the processed metal products can include sheet metal (e.g., an aluminum alloy sheet metal product), roll-formed metal products, including tubes (e.g., a roll-formed and welded aluminum alloy tube), or other suitable processed metal products.

[0022] Optionally, a quenching operation can be performed in conjunction with the simultaneous solution heat treatment operation or continuous annealing operation and surface treatment operation. For example, the quenching operation can be performed subsequent to the simultaneous solution heat treatment operation or continuous annealing operation and surface treatment operation. The quenching operation, individually or in combination with the simultaneous solution heat treatment operation or continuous annealing operation and surface treatment operation, can create a surface layer on the elongated metal substrate. In some examples, alternative to or in addition to the quenching operation, the simultaneous solution heat treatment operation or continuous annealing operation and surface treatment operation can create the surface layer on the elongated metal substrate. The surface layer can include various elements and materials for various purposes. For example, the surface layer can include inhibitors for preventing or mitigating corrosion, or can correspond to or include stable phases of the base-metal alloy (e.g., stable aluminum phases) or stable oxide or hydrolyzed oxide phases, or can include other suitable elements and materials for improving characteristics or performance associated with the elongated metal substrate.

Definitions and Descriptions

[0023] As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0024] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “7xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0025] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0026] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about ? mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0027] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0028] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, orHX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition ortemper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition ortemper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0029] As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

[0030] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C. As used herein, the meaning of “ambient conditions” can include temperatures of about room temperature, relative humidity of from about 20 % to about 100 %, and barometric pressure of from about 975 millibar (mb ar) to about 1050 mbar. For example, relative humidity can be about 20 %, about 21 %, about 22 %, about 23 %, about 24 %, about 25 %, about 26 %, about 27 %, about 28 %, about 29 %, about 30 %, about 31 %, about 32 %, about 33 %, about 34 %, about 35 %, about 36 %, about 37 %, about 38 %, about 39 %, about 40 %, about 41 %, about 42 %, about 43 %, about 44 %, about 45 %, about 46 %, about 47 %, about 48 %, about 49 %, about 50 %, about 51 %, about 52 %, about 53 %, about 54 %, about 55 %, about 56 %, about 57 %, about 58 %, about 59 %, about 60 %, about 61 %, about 62 %, about 63 %, about 64 %, about 65 %, about 66 %, about 67 %, about 68 %, about 69 %, about 70 %, about 71 %, about 72 %, about 73 %, about 74 %, about 75 %, about 76 %, about 77 %, about 78 %, about 79 %, about 80 %, about 81 %, about 82%, about 83 %, about 84 %, about 85 %, about 86 %, about 87 %, about 88 %, about 89 %, about 90 %, about 91 %, about 92 %, about 93 %, about 94 %, about 95 %, about 96 %, about 97 %, about 98 %, about 99 %, about 100 %, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.

[0031] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of“ l to 10” shouldbe considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and endingwith a maximum valueof 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt. %).

[0032] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0033] In the following examples, aluminum alloy products and their components may be described in terms of their elemental composition in weight percent (wt. %). In each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of all impurities.

[0034] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.

[0035] Unavoidable impurities, including materials or elements may be present in an alloy in minor amounts due to inherent properties of aluminum or leaching from contact with processing equipment. Some alloys, as described, may contain no more than about 0.25 wt. % of any element besides the alloying elements, incidental elements, and unavoidable impurities.

Methods of Producing the Alloys and Aluminum Alloy Products

[0036] The alloys described herein can be cast using any suitable casting method known to those of ordinary skill in the art. As a few non-limiting examples, the casting process can include a direct chill (DC) casting process or a continuous casting (CC) process. The continuous casting system can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls orblocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0037] A clad layer can be attached to a core layer to form a cladded product by any means known to persons of ordinary skill in the art. For example, a clad layer can be attached to a core layerby directchill co-casting (i.e., fusion casting) as describedin, for example, U.S. PatentNos. 7,748,434 and 8,927,113, both of which are hereby incorporated by reference in their entireties; by hot and cold rolling a composite cast ingot as described in U.S. Patent No. 7,472,740, which is hereby incorporated by reference in its entirety; or by roll bonding to achieve metallurgical bonding between the core and the cladding. The initial dimensions and final dimensions of the clad aluminum alloy products described herein can be determined by the desired properties of the overall final product.

[0038] A roll bonding process can be carried out in different manners. For example, the roll-bonding process can include both hot rolling and cold rolling. Further, the roll bonding process can be a one-step process or a multi-step process in which the material is gauged down during successive rolling steps. Separate rolling steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, and the like.

[0039] A cast ingot, cast slab, or other cast product can be processed by any suitable means. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, continuous annealing, solution heat treatment, and an optional pre-aging step. [0040] In a homogenization step, a cast product is heated to a temperature ranging from about 400 °C to about 560 °C. For example, the cast product can be heated to a temperature of about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, about 470 °C, about 480 °C, about 490 °C, about 500 °C, about 510 °C, about 520 °C, about 530 °C, about 540 °C, about 550 °C, or about 560 °C. In some examples, homogenization is performed at a temperature within 50 °C of a solidus temperature of the cast product or alloy thereof. The product is then allowed to soak(i.e., held at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time for the homogenization step, including the heating and soaking phases, can be up to 24 hours. For example, the product can be heated up to 500 °C and soaked, for a total time of up to 18 hours for the homogenization step. Optionally, the product can be heated to below 490 °C and soaked, for a total time of greater than 18 hours for the homogenization step. In some cases, the homogenization step comprises multiple processes. In some non-limiting examples, the homogenization step includes heating a cast product to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, a cast product can be heated to about 465 °C for about 3.5 hours and then heated to about 480 °C for about 6 hours.

[0041] Following a homogenization step, a hot rolling step can be performed. Prior to the start of hot rolling, the homogenized product can be allowed to cool to a temperature between 300 °C to 450 °C. For example, the homogenized product can be allowed to cool to a temperature of between 325 °C to 425 °C or from 350 °C to 400 °C. The homogenized product can then be hot rolled at a temperature between 300 °C to 450 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 3 mm and 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between).

[0042] Optionally, the cast product can be a continuously cast product that can be allowed to cool to a temperature between 300 °C to 450 °C. For example, the continuously cast product can be allowed to cool to a temperature of between 325 °C to 425 °C or from 350 °C to 400 °C. The continuously cast products can then be hot rolled at a temperature between 300 °C to 450 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 3 mm and 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product upon exit from the hot rolling mill is no more than 470 °C, no more than 450 °C, no more than 440 °C, or no more than 430 °C.

[0043] Cast, homogenized, or hot-rolled products can be cold rolled using cold rolling mills into thinner products, such as a cold rolled sheet. The cold rolled product can have a gauge between about 0.5 to 10 mm, e.g., between about 0.7 to 6.5 mm. Optionally, the cold rolled product can have a gauge of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, or 10.0 mm. The cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to 85 % (e.g., up to 10 %, up to 20 %, up to 30 %, up to 40 %, up to 50 %, up to 60 %, up to 70 %, up to 80 %, or up to 85 % reduction) as compared to a gauge prior to the start of cold rolling. Optionally, an interannealing step can be performed during the cold rolling step, such as where a first cold rolling process is applied, followed by an annealing process (interannealing), followed by a second cold rolling process. The interannealing step can be performed at a temperature of from about 300 °C to about 450 °C (e.g., about 310 °C, about 320 °C, about 330 °C, about 340 °C, about 350 °C, about 360 °C, about 370 °C, about 380 °C, about 390 °C, about400 °C, about410 °C, about 420 °C, about430 °C, about 440 °C, or about 450 °C). In some cases, the interannealing step comprises multiple processes. In some non-limiting examples, the interannealing step includes heating the partially cold rolled product to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, the partially cold rolled product can be heated to about 410 °C for about 1 hour and then heated to about 330 °C for about 2 hours.

[0044] Subsequently, a cast, homogenized, or rolled product can undergo a solution heat treatment step. The solution heat treatment step can be any suitable treatment for the sheet which results in solutionizing of the soluble particles. The cast, homogenized, or rolled product can be heated to a peak metal temperature (PMT) of up to 590 °C (e.g., from 400 °C to 590 °C) and soaked for a period of time at the PMT to form a hot product. For example, the cast, homogenized, or rolled product can be soaked at 480 °C for a soak time of up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes, or 30 minutes). After heating and soaking, the hot product is rapidly cooled at rates greater than 200 °C/s to a temperature between 500 and 200 °C to form a heat- treated product. In one example, the hot product is cooled at a quench rate of above 200 °C/second at temperatures between450 °C and 200 °C. Optionally, the coolingrates can be faster in other cases.

[0045] After quenching, the heat-treated product can optionally undergo a pre-aging treatment by reheating before coiling. The pre-aging treatment can be performed at a temperature of from about 70 °C to about 125 °C for a period of time of up to 6 hours. For example, the pre-aging treatment can be performed at a temperature of about 70 °C, about 75 °C, about 80 °C, about 85 °C, about 90 °C, about 95 °C, about 100 °C, about 105 °C, about 110 °C, about 115 °C, about 120 °C, or about 125 °C. Optionally, the pre-aging treatment can be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. The pre-aging treatment can be carried out by passing the heat-treated product through a heating device, such as a device that emits radiant heat, convective heat, induction heat, infrared heat, or the like.

[0046] The cast products described herein can be used to make products in the form of sheets, plates, or other suitable products. For example, plates including the products as described herein can be prepared by processing an ingot in a homogenization step or casting a product in a continuous caster followed by a hot rolling step. In the hot rolling step, the cast product can be hot rolled to a 200 mm thick gauge or less (e.g., from about 10 mm to about 200 mm). For example, the cast product can be hot rolled to a plate having a final gauge thickness of about 10 mm to about 175 mm, about 15 mm to about 150 mm, about 20 mm to about 125 mm, about 25 mm to about 100 mm, about 30 mm to about 75 mm, or about 35 mm to about 50 mm. In some cases, plates may be rolled into thinner metal products, such as sheets.

Methods and Systems for Making Metal Products

[0047] Metal substrates, such as metal sheets, shates, and plates, may be used for a variety of applications. In some cases, metal substrates may be used to make formed metal products through one or more forming processes, such as stamping or roll-forming. Rollforming refers to a process in which a metal substrate, such as an elongated metal substrate, is subjected to a bending operation where two or more rollers force the elongated metal substrate to undergo plastic deformation along a longitudinal or rolling axis of the substrate as it moves between the rollers. Elongated metal substrates may be in the form of a coil of sheet metal, for example, which canbe used for a variety of applications, including preparing sheet metal blanks, which can be stamped, shaped, or otherwise processed. Elongated metal substrates, like sheetmetal coils, are typically used for roll-forming operations, as rollforming can be a continuous or semi-continuous process in which long lengths of metal substrates are processed to bend the metal substrate the same way along a longitudinal (i.e., the longest) axis of the substrate. As used herein, an elongated metal substrate refers to a metal substrate having a length that is greater than a width. In some cases, a length of an elongated metal substrate may be 1 .5-1000 times (or more) the width of the substrate. For example, a metal coil may be hundreds of meters long, but only a few or a fraction of a meter wide. In some examples, a metal coil can be bent at one or more points along its width but entirely along its length by roll-forming. In some cases, an elongated metal substrate may be referred to as a metal strip. Roll-formed metal products may be sectioned into shorter segments. Elongated metal substrates may be sectioned into smaller portions, where a length and width may be comparable (e.g., ratio of length to width may be from about 0.5 to about 1.5), which may be referred to herein as a metal blank. Metal substrates, such as metal blanks, subjected to forming by stamping may be referred to herein as stamped products or stamped metal products. Metal substrates subjected to roll-forming may be referred to herein as roll-formed products or roll-formed metal products.

[0048] The elongated metal substrate may be subjected to one or more processes prior to or after forming, or generally as part of the manufacturing process for the elongated metal substrate. For example, the elongated metal substrate can be subjected to a continuous annealing process, solution heat treatment process, a surface treatment process, a quenching process, or any combination thereof. In some examples, the elongated metal substrate can be subjected to the listed processes in a defined order (e.g., the solution heat treat process or continuous annealing process, then the surface treatment process, then the quenching process, etc.). However, individually performing the processes can reduce an efficiency of producing the roll-formed metal products. For example, an amount of time, energy, or other resources used for creating the roll-formed metal product may be excessively high. Additionally, by performing the processes individually, additional processing may need to be performed to form a processed metal product such as sheet metal or a roll-formed metal object, such as a tube. For example, performing a solution heat treatment operation or continuous annealing operation subsequentto a surface treatment operation may destroy or otherwise degrade the effectiveness of the surface treatment operation, and this may necessitate an additional surface treatment operation.

[0049] The techniques described herein, however, allow for more than one process to be performed simultaneously during preparation of the processed metal product. For example, the solution heat treatment operation or continuous annealing operation and the surface treatment operation can be performed simultaneously. By performing the solution heat treatment operation or continuous annealing operation and the surface treatment operation simultaneously, the efficiency of creating the resulting processed metal product may increase and the processed metal product may include improved characteristics (e.g., bond durability, hardness, strength, surface characteristics, etc.).

[0050] FIG. 1 provides a schematic illustration of an exemplary processing line 100 for forming processed metal products from an elongated metal substrate. In some examples, the processing line 100 can be configured to produce processed metal products that can include sheet metal (e.g., aluminum alloy or other suitable alloy sheet metal). The processing line 100 can include a furnace, a step, a station, or other suitable component that can simultaneously perform solution heat treatment or continuous annealing and surface treatment operations with respect to the elongated metal substrate.

[0051] As illustrated, the processing line 100 includestwo starting coils (e.g., starting coil 102), various rollers 104, an elongated metal substrate 105, a furnace 106, a quenching station 108, a tension leveler 110, a pre-ageing station 112, and an ending coil 114. The elongated metal substrate 105 can extend from the starting coil 102 to the ending coil 114 (e.g., passing through each component of the processing line 100 for preparing the processed metal product). The rollers 104 can aid in transporting the elongated metal substrate 105. [0052] The furnace 106 can perform a solution heat treatment operation or continuous annealing operation and a surface treatment operation. In some examples, the furnace 106 can simultaneously perform the solution heat treatment operation or continuous annealing operation and the surface treatment operation. The solution heat treatment operation or continuous annealing operation can involve heating the elongated metal substrate 105 to a suitable temperature for dissolving alloying elements into the elongated metal substrate 105, for improving characteristics or performance with respect to the elongated metal substrate 105, for modifying a temper of the elongated metal substrate, or the like. The surface treatment operation can involve one or more operations for altering a natural surface of the elongated metal substrate 105, such as to produce a surface layer, to improve an adhesion characteristic, or the like of the elongated metal substrate 105. In some examples, the furnace 106 can use super-heated steam to perform a simultaneous heat treatment or continuous annealing and surface treatment operation. The super-heated steam can be applied to the elongated metal substrate 105 via nozzles or other suitable sources for the super-heated steam. Optionally, the super-heated steam canbe defined by a low moisture content (e.g., less than 10%). In some examples, the super-heated steam can include additives (e.g., inhibitors, acids, etc.) for performing the surface treatment operation or for otherwise improving characteristics or performance of the elongated metal substrate 105. In some examples, in response to the simultaneous solution heat treatment or continuous annealing and surface treatment operation, no further surface treatment operation may be required to produce the processed metal product with the processing line 100.

[0053] The quenching station 108 can apply water or other suitable quenching solutions for quenching the elongated metal substrate 105. In some examples, the elongated metal substrate 105 can be subjected to a quenching process at the quenching station 108 subsequent to the simultaneous solution heat treatment or continuous annealing and surface treatment operation at the furnace 106. The quenching process can involve subjecting the elongated metal substrate 105 to the water or quenching solution for cooling the elongated metal substrate 105 without losing improved characteristics or performance traits provided by the simultaneous solution heat treatment or continuous annealing and surface treatment operation. In some examples, the quenching solution can include additives, such as inhibitors, acids, etc., for improving characteristics or performance traits of the elongated metal substrate 105.

[0054] FIG. 2 provides a schematic illustration of an exemplary processing line 200 for roll-forming a metal product from an elongated metal substrate 205. In some examples, the processing line 200 can be configured to produce a processed metal product such as metal tubes (e.g., aluminum alloy or other suitable alloy roll-formed metal tube), where ends of a roll-formed metal substrate are welded to produce a closed shape, or other roll-formed metal products. Similar to the processing line 100, the processing line 200 can include a furnace, a step, or a station that can simultaneously perform solution heat treatment or continuous annealing and surface treatment operations with respect to the elongated metal substrate 205. [0055] As illustrated, the processing line 200 includes starting coil 201 , roll forming station 206, a welding station 208, a scarfing station 210, a post-weld heat treatment station 212, and a quench bath 214. The starting coil 201 can be similar or identical to the starting coil 102 of the processing line 100. The roll forming station 206 can include one or more rollforming stands that can be used to form the elongated metal substrate 205, such as into a tubular-shaped elongated metal substrate 207. The welding station 208 can perform one or more optional welding operations relating to the elongated metal substrate 205. For example, subsequent to forming the tubular shape at the roll-forming station 206, the processing line 200 can use the welding station 208 to weld the elongated metal substrate 205 to produce a tubular shape (e.g., an open tube, a closed tube, or other suitable shape). Optionally, a forging process can be performed (e.g., using one or more roll-forging stands) subsequent to the welding station 208. The scarfing station 210 can be used to scarf a surface of the tubularshaped elongated metal substrate 207. Scarfing can involve removing defects (e.g., burrs, nicks, etc.) from one or more surfaces of the elongated metal substrate 205.

[0056] The heat treatment station 212 can optionally be used to perform simultaneous heat treatment and surface treatment operations. For example, the heat treatment station 212 can use super-heated steam to perform the simultaneous heat treatment and surface treatment operation. In some examples, the heat treatment station 212 can optionally be a post-weld heat treatment station. While illustrated subsequent to the welding station 208, the heat treatment station 212 can be performed at any suitable point with respect to the processing line 200. In some examples, the heat treatment station 212 can use flame pyrolysis, induction heating, exposure to super-heated steam, or other suitable operations, or a combination thereof to perform the simultaneous heat treatment and surface treatment operation. In some examples, flame pyrolysis can involve burning fuel (e.g., using gas burners) to heat the elongated metal substrate 205. Flame pyrolysis can be usedin combination with steam nozzles that can spray super-heated steam on the elongated metal substrate 205 to create stable phases of the substrate base-alloy (e.g., an aluminum alloy). In some examples, the combination of the flame pyrolysis and the steam nozzles can include inhibitors, acids, or other suitable additives for use in applying the additives to the surface of the elongated metal substrate 205 via the steam nozzles or flame pyrolysis.

[0057] The quench bath 214 can include a quenching solution. In some examples, the quenching solution of the quench bath 214 can be similar or identical to the quenching solution of the quenching station 108 of the processing line 100. For example, the quenching solution optionally can include additives, such as inhibitors, acids, etc., for improving characteristics or performance traits of the elongated metal substrate 205. The tubular-shaped, elongated metal substrate 205 canbe subjected to a quenching process with respect to the quench bath 214 subsequent to the simultaneous solution heat treatment or continuous annealing and surface treatment operation at the heat treat station 212. The quenching process can involve subjecting the elongated metal substrate 205 to the quenching solution for cooling the elongated metal substrate 205 without losing improved characteristics or performance traits provided by the simultaneous solution heat treatment or continuous annealing and surface treatment operation. In some examples, the quench bath 214 can involve reactive quenching with a quenching solution including one or more salts, decomposable surface treatment precursors (e.g., polymer precursors, etc.), other suitable reactive quenching material, or a combination thereof.

[0058] In some examples, the quenching solution (e.g., of the quenching station 108 and/or the quench bath 214) can include additives. The additives can include inorganic or organic surface enhancing components that can include Zr, Mn, Ce, Mo, silicates, phosphates, silanes, or other suitable surface enhancing components. The quenching solution with the additives can be used to cool the elongated metal substrate 205 and to seal a surface layer that can be produced by the simultaneous solution heat treatment or continuous annealing and surface treatment operation. In some examples, the quenching solution canbe used to include the additives into the surface layer for increasing performance characteristics (e.g., hardness, corrosion-resistance, bond durability, etc.) of the elongated metal substrate 205.

[0059] While described above as sheet metal, a roll-formed sheet metal product, a roll- formed sheetmetal tube, or a combination thereof, the elongated metal substrate 105 or 205 can include various materials regardless of configuration. For example, the sheet metal configuration of the elongated metal substrate 105 can include one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. Additionally, the roll-formed sheet metal tube configuration of the elongated metal tube 207 can include one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. The elongated metal substrate 105 can include additional other suitable alloys. Additionally, the processed metal product produced from the processing lines 100 and 200 can exhibit similar performance characteristics. For example, the processing line 100 or 200 can produce a processed metal product that exhibits an improvement to a bond durability characteristic as compared to processed metal products that are produced in substantially the same way but without performing surface treatment, such as where the elongated metal substrate is not subjected to superheated steam during a solution heat treatment or continuous annealing operation. In some examples, bond durability may be determined according to an ASTM D3762 standard test or a FLTM B V 101-07 standard test. In some examples, the processed metal product can exhibit a bond durability of from 30 cycles to 65 cycles or more. [0060] FIG. 3 provides a schematic illustration of a sub -system 300 of the processing line 200 for producing processed metal products using simultaneous solution heat treatment or continuous annealing and solution treatment operations. The elongated metal substrate 205 is illustrated as moving along direction 310 through the sub-system 300. The sub-system 300 can include a roll-forming stand 305, an optional welding station 315, a set of magnetic field sources 320, a set of flame pyrolysis sources 335, and a set of steam nozzles 350. A bent metal product 330 can exit the sub-system 300 after passing through sub-system 300. Although the elongated metal substrate 205 is shown as originating from a coil, other configurations may include processingthe elongated metal substrate 205 as a metal blank or a metal strip. Additionally, although the elongated metal substrate 205 is shown as a flat sheet, other configurations are possible (e.g., a tubular-shaped, elongated metal substrate 207, etc.). [0061] The roll-forming stand 305 may include two or more rollers driven along independent rotation axes in a configuration to receive and pass the elongated metal substrate 205 between the rollers. The rollers may include roller surfaces with surface profiles relatively oriented with respect to each other for bending, in a direction different from the direction 310, the elongated metal substrate 205 as it passes between the rollers along the direction 310. Optionally, the roll-forming stand 305 can include a top roller having a top rotation axis and a top roller surface and a bottom roller having a bottom rotation axis and a bottom roller surface. Optionally, other roller configurations may be included in the rollforming stand 305, such as a forming roller oriented with respect to a top roller or a bottom roller with a rotation axis and surface profile positioned relative to other rollers to bend the elongated metal substrate 205 as it passes through the roll-forming stand 305. The welding station 315 may be optional and may allow the elongated metal substrate 205 to be formed into various shapes. For example, the welding station 315 may allow the elongated metal substrate 205 to becomethe tubular-shaped elongated metal substrate 207 or any other suitable shape forthe elongated metal substrate 205.

[0062] Each magnetic field source 320 may generate a time-varying magnetic field to heat a portion of the elongated metal substrate 205 via induction heating. Each flame pyrolysis source 335 may expose a portion of the elongated metal substrate 205 to heat (or other suitable outputs from a flame pyrolysis system). Each steam nozzle 350 may expose a portion of the elongated metal substrate 205 to super-heated steam and, optionally, various additives. Depending on the configuration, different portions of elongated metal substrate 205 may be heated by the different magnetic field sources 320, flame pyrolysis sources 335, and/or steam nozzles. The magnetic field sources 320, the flame pyrolysis sources 335, and/or the steam nozzles 350 may be positioned before and/or after the roll-forming stand 305. As illustrated, the magnetic field sources 320, the flame pyrolysis sources335, and the steam nozzles 350 are positioned afterthe roll-forming stand 305 but they need not be in other embodiments and may be positioned in any suitable location with respect to the subsystem 300. The magnetic field sources 320, the flame pyrolysis sources 335, and/or the steam nozzles 350 may be independently positioned on a top side or bottom side of the elongated metal substrate 205. A position of the magnetic field sources 320, the flame pyrolysis sources 335, and/orthe steam nozzles 350 may, at leastin part, be governedby the particular bend operation achieved by the roll-forming stand 305. For example, an interior bend surface of elongated metal substrate 205 may face a magnetic field source 320, a flame pyrolysis source 335, a steam nozzle 350, or a combination thereof positioned afterthe rollforming stand 305. Although a combination of magnetic field sources 320, flame pyrolysis sources 335, and steam nozzles 350 are shown in the sub-system 300, the magnetic field sources 320, the flame pyrolysis sources 335, and the steam nozzles 350 may be used alone or in any combination in any desirable number. For example, the sub-system 300 may include one or more magnetic field sources 320, one or more steam nozzles 350 and no flame pyrolysis sources 335. As another example, the sub-system 300 may include one ormore flame pyrolysis sources 335, one or more steam nozzles 350, and no magnetic field sources 320.

[0063] In some examples, the steam nozzles 350 may apply super-heated steam that includes additives, such as inhibitors, to the elongated metal substrate 205. The additives can include inhibitors such as Mn, Ce, Zr, Mo, other suitable inhibiting elements or compounds, or a combination thereof. Additionally or alternatively, the additives can include acids, HN0 ₃ , or other suitable acids or inhibiting compounds. The additives can alter a natural surface of the elongated metal substrate 205, such as to produce a surface layer, to improve an adhesion characteristic, or the like of the elongated metal substrate 205.

[0064] The heating may involve performing the solution heat treating or continuous annealing and surface treatment operations. In this example, the heating may modify a natural surface of the elongated metal substrate 205, such as to produce a surface layer, to improve an adhesion characteristic, or the like of the elongated metal substrate 205. The heating may increase a temperature of a portion of elongated metal substrate 205 to or above a temperature sufficient to, temporarily or permanently, increase formability or plasticity of the portion of the elongated metal substrate 205. In some cases, the heating may be of a sufficient time duration to modify a temper of the portion of the elongated metal substrate 205. Optionally, the heating may overage the portion of the elongated metal substrate 205. The heating may raise the temperature of the portion of the elongated metal substrate 205 to, for example, between 50 °C and 400 °C, such as between 100 °C and 300 °C.

[0065] FIG. 4 provides a sectional side-view of components 400 of a furnace (e.g., the furnace 106 of the processing line 100) that can be used to simultaneously perform solution heat treatment or continuous annealing and surface treatment operations. Various components 400 of the furnace are illustrated and can include a set of steam nozzles 402, a set of nozzle boxes 404 (e.g., containing natural gas burner nozzles), and other suitable components of the furnace. As illustrated, each steam nozzle 402 can be positioned opposite a nozzle box 404. Additionally as illustrated, the steam nozzles 402 and the nozzle boxes 404 are alternating in the furnace, though this need not be the case and other configurations are contemplated. The elongated metal substrate can be positioned in a middle portion of the furnace such that the steam nozzles 402 and the nozzle boxes 404 can apply, to the elongated metal substrate 105, super-heated steam, heat, or other suitable outputs from the steam nozzles 402 or the nozzle boxes 404. The elongated metal substrate can be passed through the furnace and can receive tension force such that, while the elongated metal substrateis in the furnace, the elongated metal substrate may be taut or otherwise flat for receiving the super-heated steam.

[0066] In some examples, the steam nozzles 402 can spray or otherwise suitably apply the super-heated steam to one or more portions of the elongated metal substrate. The superheated steam can be dry or may include a limited amount of moisture content (e.g., less than 10%). The super-heated steam can be used to perform the simultaneous heat treatment and surface treatment operation. The simultaneous heat treatment and surface treatment operation can cause a surface lay er to be produced on the elongated metal substrate . [0067] The surface layer can include stable, or otherwise suitable, phases or modified layers of a base-metal of the alloy of the elongated metal substrate. In an example in which the elongated metal substrate includes an aluminum alloy, the stable phase may include an aluminum oxide or a hydrolyzed aluminum oxide phase (e.g., boehmite, diaspore, etc.). The stable phase may be present as a surface layer and may optionally increase the corrosionresistance, adhesion to subsequent coatings, or the bond durability performance indicators associated with the elongated metal substrate. In some examples, the super-heated steam can include additives such as the inhibitors described above. The inhibitors can combine with the stable phase of the surface layer and can further increase characteristics or other suitable performance indicators of the elongated metal substrate. For example, the inhibitors and the stable phase can be deposited simultaneously by the steam nozzles 402 and the nozzle boxes 404 for increasing the performance indicators of the elongated metal substrate .

[0068] The nozzle boxes 404 can include nozzles separate from the steam nozzle 402, can include natural gas burners, or can include other suitable components for the nozzle boxes 404. The nozzle boxes 404 can provide heatto the elongated metal substrate 105, for example, via the super-heated steam, the heat from burning the natural gas, or other suitable heat source. While four steam nozzles 402 and four nozzle boxes 404 are illustrated, any suitable amount of steam nozzles 402 and nozzle boxes 404 can be included in the furnace, or in any portion or sub-part thereof, for simultaneously solution heat treating or continuous annealing and surface treating the elongated metal substrate .

[0069] In some examples, the furnace can include more than one zone. For example, the components 400 illustrated in FIG. 4 can be included in a first zone, and a second zone can include a second set of components, etc. The furnace can include any suitable amount of zones. For example, the furnace can include nine zones, 10 zones, 11 zones, 12 zones, or other suitable amount of zones for performing the simultaneous solution heat treatment or continuous annealing and surface treatment operation. Optionally, cleaning the elongated metal substrate, such as by using hot water, alkaline cleaners, or the like, may be performed prior to a solution heat treatment or continuous annealing operation. In some examples, one or more zones within a furnace may be used for cleaning, such as to remove oil, soil, dirt, dust, debris, or the like from the surface. After a cleaning process, simultaneous surface treatment and solution heat treatment or continuous annealing may be performed.

[0070] FIG. 5 provides a flowchart of a process 500 to create a processed metal product by simultaneously performing solution heat treatment or continuous annealing and surface treatment operations using super-heated steam. At block 502, an elongated metal substrate is subjected to a solution heat treatment operation or continuous annealing operation. And, at block 504, the elongated metal substrate is subjected to a surface treatment operation. In some examples, the solution heat treatment or continuous annealing process of the block 502 and the surface treatment operation of the block 504 can be performed simultaneously.

[0071] In some example, the solution heat treatment or continuous annealing process of the block 502 and the surface treatment operation ofthe block 504 can be performed using super-heated steam using a furnace (e.g., using the steam nozzles 402), using a flame pyrolysis operation (e.g., using the flame pyrolysis source 335), or using other suitable techniques. The super-heated steam can be applied to a surface of the elongated metal substrate to produce a surface layer of the elongated metal substrate. The surface layer can include one or more stable phases or layers of a base-metal of the elongated metal substrate. For example, if the elongated metal substrate includes an aluminum alloy, the stable phases included in the surface layer can include boehmite (y — A100H), diaspore (a — A100H), or other suitable stable phases of aluminum.

[0072] At block 506, the elongated metal substrate is optionally subjected to a quenching solution. The quenching solution can include pure water, water with additives, or other suitable quenching solutions. The quenching solution can be used to cool the elongated metal substrate sub sequent to the simultaneous solution heat treatment or continuous annealing and surface treatment operation while retaining the surface layer (and other performance indicator improvements) producedby the operationsof the blocks 502 and 504.

[0073] In some examples, additives can be included in the super-heated steam, the quenching solution, or in other mediums to which the elongated metal substrate can be subjected. The additivescan include one or more inhibitors, organic surface enhancers, inorganic surface enhancers, or other suitable additives. The inhibitorscan include Mn, Ce, Zr, Mo, acids, or other suitable inhibiting elements or compounds. The organic and inorganic surface enhancers can include phosphates, silicates, silanes, or other suitable organic or inorganic surface enhancers. The additives can be included in the super-heated steam, the quenching solution, in other mediums to which the elongated metal substrate can be subjected, or a combination thereof for combining with the stable phases ofthe surface lay er or for otherwise improving performance indicators (e.g., corrosion resistance, bond durability, etc.) of the elongated metal substrate.

[0074] FIG. 6 provides a sectional side-view of a processed metal product 600 having a surface layer 602 that can be created by simultaneously performing solution heat treatment or continuous annealing and surface treatment operations with respect to the processed metal product. The processed metal product 600 can additionally include a substrate 604 that can be a portion of the elongated metal substrate 105. The substrate 604 can include a metal alloy such as an aluminum alloy. The surface layer 602 can include one or more stable phases of the base-metal of the substrate 604. In an example in which the substrate 604 includes an aluminum alloy, the surface layer 602 can include stable phases of aluminum (e.g., boehmite, diaspore, and corundum, etc.). The surface layer 602 can additionally include inhibitors or other surface enhancers. For example, the super-heated steam and quenching solution applied to the elongated metal substrate during the simultaneous solution heat treatment or continuous annealing and surface treatment operation can include inhibitors (e.g., Mn, Ce, Zr, Mo, acids, etc.), surface enhancers (e.g., phosphates, silicates, silanes, etc.), or a combination thereof. The inhibitors and surface enhancers can combine with, or be applied to the elongated metal substrate simultaneously with respect to, the stable phases for improving performance indicators or characteristics with respect to the processed metal product 600. [0075] The substrate 604 can include an aluminum alloy or other suitable substrate material. For example, the substrate 604 can include a 2xxx alloy, a 5xxx alloy, a 6xxx alloy, a 7xxx alloy, or other suitable alloy for the substrate 604. Additionally, the surface layer 602 can be produced on the substrate 604 and a thickness of the surface layer 602 can be from 10 nm to 500 nm. For example, the surface layer 602 can be from 10 nm to 450 nm, from 10 nm to 400 nm, from 10 nm to 350 nm, from 10 nm to 300 nm, from 10 nm to 250 nm, from 10 nm to 200 nm, from 10 nm to 150 nm, from 10 nm to 100 nm, from 10 nm to 50 nm, from 50 nm to 100 nm, from 100 nm to 150 nm, from 150 nm to 200 nm, from 200 nm to 250 nm, from 250 nm to 300 nm, from 300 nm to 350 nm, from 350 nm to 400 nm, from 400 nm to 450 nm, from 450 nm to 500 nm, or other suitable range from 10 nmto 500 nm.

Methods of Using Metal Products

[0076] The aluminum alloy products described herein can be used in automotive applications and other transportation applications, including aircraft and railway applications. For example, the disclosed aluminum alloy products can be used to prepare automotive structural parts, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels. [0077] The aluminum alloy products and methods described herein can also be used in electronics applications. For example, the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the aluminum alloy products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones), tablet bottom chassis, and other portable electronics.

Methods of Treating Metals and Me tai Alloys

[0078] Described herein are methods of treating metals and metal alloys, including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, among others, and the resultant treated metals and metal alloys. In some examples, the metals for use in the methods described herein include aluminum alloys, for example, Ixxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys. In some examples, the materials for use in the methods described herein include non-ferrous materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets usedin composites, or any other suitable metal, non-metal or combination of materials. Monolithic as well as non-monolithic, such as roll-bonded materials, cladded alloys, clad layers, composite materials, such as but not limited to carbon fiber-containing materials, or various other materials are also useful with the methods described herein. In some examples, aluminum alloys containing iron are useful with the methods described herein.

[0079] By way of non-limiting example, exemplary Ixxx series aluminum alloysforuse in the methods described herein can include AA1100, AA1100 A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

[0080] Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein can include AA2001 , AA2002, AA2004, AA2005, AA2006, AA2007, AA2007 A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011 A, AA2111, AA21 11 A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

[0081] Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, A A3005 A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065. [0082] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, orAA4147.

[0083] Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein product can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088. [0084] Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein can include AA6101, AA6101 A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6 110, AA6110 A, AA6011 , AA6111 , AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, AA6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0085] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0086] Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0087] The examples disclosed herein will serve to further illustrate aspects of the invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention. The examples and embodiments described herein may also make use of conventional procedures, unless otherwise stated. Some of the procedures are described herein for illustrative purposes.

ILLUSTRATIVE ASPECTS

[0088] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1 , 2, 3 , or 4 ”).

[0089] Aspect 1 is a method of comprising: subjecting an elongated metal substrate to a solution heat treatment process or a continuous annealing process; and subjecting the elongated metal substrate to a surface treatment process, wherein the surface treatment process and the solution heat treatment process or continuous annealing process are performed simultaneously using super-heated steam, thereby generating a processed metal product.

[0090] Aspect 2 is the method of any previous or subsequent aspect, wherein the elongated metal substrate comprises an aluminum alloy sheetmetal or a coil of an aluminum alloy sheetmetal.

[0091] Aspect 3 is the method of any previous or subsequent aspect, wherein the aluminum alloy sheet metal includes one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

[0092] Aspect 4 is the method of any previous or subsequent aspect, further comprising quenching the elongated metal substrate using a quenchant comprising water and at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant, wherein the processed metal product includes a surface layer comprising at least one of Mn, Ce, Zr, Mo, the silicate, the silane, or the sealant.

[0093] Aspect 5 is the method of any previous or subsequent aspect, wherein the superheated steam includes an inhibiting material, wherein the inhibiting material comprises at least one of Mn, Ce, Zr, or Mo, and wherein at least one of Mn, Ce, Zr, or Mo is incorporated on a surface layer of the processed metal product.

[0094] Aspect 6 is the method of any previous or subsequent aspect, wherein the processed metal product includes a surface layer formed by the solution heat treatment process or continuous annealing process and the surface treatment process, wherein the surface layer includes at least one of boehmite, bayerite, diaspore, or corundum, and wherein a thickness of the surface layer is from 10 nm to 500 nm.

[0095] Aspect 7 is the method of any previous or subsequent aspect, wherein a moisture content of the super-heated steam is less than or equal to 10%.

[0096] Aspect 8 is the method of any previous or subsequent aspect, wherein subjecting the elongated metal substrate to the solution heat treatment process or continuous annealing process and subjecting the elongated metal substrate to the surface treatment process includes passing the elongated metal substrate into a furnace, and wherein the furnace includes one or more nozzles for spraying super-heated steam onto the elongated metal substrate.

[0097] Aspect 9 is the method of any previous or subsequent aspect, wherein the elongated metal substrate comprises an aluminum alloy sheetmetal tube.

[0098] Aspect 10 is the method of any previous or subsequent aspect, further comprising preparing the aluminum alloy sheet metal tube by: roll-forming an aluminum alloy sheet metal into a tubular shape; and welding edges of the tubular shape together to enclose the aluminum alloy sheetmetal tube.

[0099] Aspect 11 is the method of any previous or subsequent aspect, wherein the aluminum alloy sheet metal tube has a circular or non-circular cross-sectional shape.

[0100] Aspect 12 is the method of any previous or subsequent aspect, wherein the solution heat treatment process or continuous annealing process and the surface treatment process are performed using a combination of flame pyrolysis and induction heating.

[0101] Aspect 13 is the method of any previous or subsequent aspect, wherein the solution heat treatment process or continuous annealing process and the surface treatment process are performed subsequentto weldingthe elongated metal substrate to form a metal tube.

[0102] Aspect 14 is a metal product comprising: an aluminum alloy sheetmetal substrate; and a surface layer on the aluminum alloy sheet metal substrate, wherein the surface layer includes at least one of boehmite, bayerite, diaspore, and corundum, and wherein a thickness of the surface layer is from 10 nm to 500 nm.

[0103] Aspect 15 is the metal product of any previous or subsequent aspect, wherein the aluminum alloy sheetmetal substrate includes one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

[0104] Aspect 16 is the metal product of any previous or subsequent aspect, wherein the aluminum alloy sheet metal substrate comprises a solution heat treated aluminum alloy sheet metal substrate or a continuously annealed aluminum alloy sheetmetal substrate. [0105] Aspect 17 is the metal product of any previous or subsequent aspect, wherein the surface layer includes at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant.

[0106] Aspect 18 is the metal product of any previous or subsequent aspect, wherein the surface layer is generated by subjecting the aluminum alloy sheetmetal substrate to superheated steam characterized by a moisture content of less than or equal to 10%.

[0107] Aspect 19 is the metal product of any previous or subsequent aspect, wherein the super-heated steam includes an inhibiting material, wherein the inhibiting material includes at least one of Mn, Ce, Zr, and Mo.

[0108] Aspect 20 is the metal product of any previous or subsequent aspect, wherein the surface layer is, at least in part, generated by exposing the aluminum alloy sheetmetal substrate to an aqueous quenchant.

[0109] Aspect 21 is the metal product of any previous or subsequent aspect, wherein the aqueous quenchant includes water and at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant.

[0110] Aspect 22 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a bond durability of from 30 cyclesto 65 cycles or more accordingto an ASTM D3762 standard test or a FLTMBV 101-07 standard test.

[0111] Aspect 23 is a tubular metal product comprising: a roll-formed aluminum alloy sheet metal tube; and a surface layer on the roll-formed aluminum alloy sheet metal tube, wherein the surface layer includes at least one of boehmite, bayerite, diaspore, and corundum, and wherein the surface layer is between 10 nm and 500 nm.

[0112] Aspect 24 is the tubular metal product of any previous or subsequent aspect, wherein the roll-formed aluminum alloy sheet metal tube includes one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

[0113] Aspect 25 is the tubular metal product of any previous or subsequent aspect, wherein the surface layer includes at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant.

[0114] Aspect 26 is the tubular metal product of any previous or subsequent aspect, wherein the roll-formed aluminum alloy sheet metal tube is prepared by: roll-forming an aluminum alloy sheetmetal into a tubular shape; and welding edges of the tubular shape together to enclose the roll-formed aluminum alloy sheetmetal tube.

[0115] Aspect 27 is the tubular metal product of any previous or subsequent aspect, wherein the roll-formed aluminum alloy sheet metal tube comprises a treated aluminum alloy sheet metal tube, subjected to simultaneous solution heat treatment or continuous annealing and surface treatment process using a combination of flame pyrolysis and induction heating subsequent to welding the edges of the tubular shape together.

[0116] Aspect 28 is the tubular metal product of any previous or subsequent aspect, wherein the metal product exhibits a bond durability of from 30 cycles to 65 cycles or more according to an ASTM D3762 standard test or aFLTM BV 101-07 standard test.

[0117] Aspect 28 is the tubular metal product of any previous or subsequent aspect, wherein the wherein the roll-formed aluminum alloy sheet metal tube has a circular or noncircular cross-sectional shape.